Specifications

Chapter 1 Engine, clutch and gearbox

36 Replacing the clutch assembly and centrifugal oil filter

1 Place the clutch outer drum in position on the gearbox

mainshaft

end, followed by the splined thrust washer and inner

clutch centre half. Fit the clutch plates, starting with a friction

plate, then a plain plate. Build up the layers of plates, finishing

with a friction plate, and ensuring that the internal splines of the

plain plates are in line. If this is not done, it will be impossible to

fit the clutch centre.

2 Lower the clutch centre into position and secure with the

circlip, then fit the clutch springs over the projecting threaded

pillars. The thrust plate can now be placed in position, and the

four retaining bolts fitted and tightened. Install the cup and

pushrod in the centre of the thrust bearing.

3 Place the inner half of the centrifugal oil filter over the

crankshaft end, followed by the special washer, noting the

markings denoting the outside face. Fit and tighten the slotted

securing nut to a torque setting of 4.0 - 5.0 kgf m (29 - 36

Ibf

ft), using the Honda service tool or improvised peg spanner.

Install a new gasket, followed by the outer half of the filter unit,

tightening the three retaining screws evenly to avoid any risk of

warpage.

4 Fit the two locating dowels into the crankcase mating

surface and place a new gasket over them, using a smear of

grease to stick it in place. Check that the clutch pushrod is in

place and the release mechanism is correctly refitted and

greased, then apply a smear of grease to the lips of the kickstart

36.1b

... and fit thrust washer

shaft oil seal. Press the crankcase right-hand cover into place,

using a few taps from a soft-faced mallet to seat it. Refit and

tighten securely and evenly the cover retaining screws. Check

that the clutch release mechanism is working properly.

36.1 a Place clutch drum in position

36.1 c ... and inner centre half

36.1

d Fit friction and plain plates as shown

36.2a Upper clutch centre half can now be fitted and

retained by circlip